Single shot molding method for COB USB/EUSB devices with contact pad ribs

RELATED APPLICATIONS

0001This application is a divisional of U.S. Patent application for “SINGLE SHOT MOLDING METHOD FOR COB USB/EUSB DEVICES WITH CONTACT PAD RIBS”, U.S. application Ser. No. 12/234,581, filed Sep. 19, 2008, now U.S. Pat. No. 8,102,657.

0002This application is also related to U.S. Patent application for “Extended COB-USB with Dual-Personality Contacts” U.S. application Ser. No. 12/124,081, filed May 20, 2008, now U.S. Pat. No. 7,872,873.

0003This application is also related to U.S. Patent application for “Direct Package Mold Process for Single Chip SD Flash Cards” U.S. application Ser. No. 12/175,753, filed Jul. 18, 2008, now abandoned.

0004This application is also related to “Assembly Including Slim Female USB Connector and Slim Male USB Connector with Spring-Engaging Depressions, Stabilizing Dividers and Wider End Rails” now U.S. Pat. No. RE40,115, and to “Manufacturing Methods for Ultra-Slim USB Flash-Memory Card with Supporting Dividers or Underside Ribs”, now U.S. Pat. No. 7,094,074.

FIELD OF THE INVENTION

0005This invention relates to portable electronic devices, and more particularly to portable electronic devices including Universal-Serial-Bus (USB) or Expanded Universal-Serial-Bus (EUSB) connections.

BACKGROUND OF THE INVENTION

0006Universal-Serial-Bus (USB) has been widely deployed as a standard bus for connecting peripherals such as digital cameras and music players to personal computers (PCs) and other devices. Currently, the top transfer rate of USB is 480 Mb/s, which is quite sufficient for most applications. Faster serial-bus interfaces are being introduced to address different requirements. PCI Express, at 2.5 Gb/s, and SATA, at 1.5 Gb/s and 3.0 Gb/s, are two examples of high-speed serial bus interfaces for the next generation devices, as are IEEE 1394 and Serial Attached Small-Computer System Interface (SCSI).

0007<figref idref="DRAWINGS">FIG. 30(A)</figref> shows a prior-art peripheral-side USB connector. USB connector <b>10</b> may be mounted on a board in the peripheral. USB connector <b>10</b> can be mounted in an opening in a plastic case (not shown) for the peripheral.

0008USB connector <b>10</b> contains a small connector substrate <b>14</b>, which is often white ceramic, black rigid plastic, or another sturdy substrate. Connector substrate <b>14</b> has four or more metal contacts <b>16</b> formed thereon. Metal contacts <b>16</b> carry the USB signals generated or received by a controller chip in the peripheral. USB signals include power, ground, and serial differential data D+, D−.

0009USB connector <b>10</b> contains a metal case that wraps around connector substrate <b>14</b>. The metal case touches connector substrate <b>14</b> on three of the sides of connector substrate <b>14</b>. The top side of connector substrate <b>14</b>, holding metal contacts <b>16</b>, has a large gap to the top of the metal case. On the top and bottom of this metal wrap are formed holes <b>12</b>. USB connector <b>10</b> is a male connector, such as a type-A USB connector.

0010<figref idref="DRAWINGS">FIG. 30(B)</figref> shows a female USB connector. Female USB connector <b>20</b> can be an integral part of a host or PC, or can be connected by a cable. Another connector substrate <b>22</b> contains four metal contacts <b>24</b> that make electrical contact with the four metal contacts <b>16</b> of the male USB connector <b>10</b> of <figref idref="DRAWINGS">FIG. 30(A)</figref>. Connector substrate <b>22</b> is wrapped by a metal case, but small gaps are between the metal case and connector substrate <b>22</b> on the lower three sides.

0011Locking is provided by metal springs <b>18</b> in the top and bottom of the metal case. When male USB connector <b>10</b> of <figref idref="DRAWINGS">FIG. 30(A)</figref> is flipped over and inserted into Female USB connector <b>20</b> of <figref idref="DRAWINGS">FIG. 30(B)</figref>, metal springs <b>18</b> lock into holes <b>12</b> of male USB connector <b>10</b>. This allows the metal casings to be connected together and grounded.

0012Other bus interfaces offer higher transfer rates than USB devices, which have a top transfer rate of 480 Mb/s. For example, Peripheral-Component-Interconnect (PCI) Express (2.5 Gb/s) and Serial-Advanced-Technology-Attachment (SATA) (1.5 Gb/s and 3.0 Gb/s) are two examples of high-speed serial bus interfaces for next generation devices. IEEE 1394 (Firewire) supports 3.2 Gb/s. Serial Attached Small-Computer System Interface (SCSI) supports 1.5 Gb/s. These high speed interfaces renders standard USB devices undesirable for some applications.

0013What is needed is a high speed USB flash memory device using a single dual-personality flexible system that supports both standard Universal-Serial-Bus (USB) devices and a higher speed USB targeted at 5.0 Gb/S with the addition of extra transmit and receive signal pairs, plus a ground line that serves as separating line to the two communication signal pairs that make up the extended five additional pins.

SUMMARY OF THE INVENTION

0014The present invention is directed to both standard USB 2.0 devices and high speed extended USB (EUSB) devices in which a printed circuit board assembly (PCBA) is encased within a single-shot molded housing. According to an aspect of the present invention, the PCBA includes a PCB having standard USB metal contact pads disposed on a top (first) surface, and all passive components and integrated circuits (ICs) mounted on a bottom (second) surface. In accordance with an aspect of the invention, single-shot molded housing is formed in a single shot molding process such that a thin top (first) portion of the housing is formed on the first surface of the PCBA, and a second portion of the housing is formed on the second surface of the PCBA such that the passive components and ICs are encased by the bottom portion. By utilizing a single shot molding process to form the single-shot molded housing over the PCBA, the present invention provides an inexpensive manufacturing method (i.e., lower cost and high assembly throughput when compared with assembly using external shell casings) that also provides greater moisture and water resistance and higher impact force resistance than that achieved using conventional manufacturing methods. In accordance with another aspect of the invention, the top portion of the molded housing is formed with elongated ribs that extend between associated pairs of the standard USB metal contact pads. These ribs provide the advantage of serving as a guide for host connector pins to avoid shorting to adjacent pins when the USB device is slanted at an angle in the host socket, and also serve to prevent undesirable wear of the standard USB metal contact pads due to repeated insertion into a host socket.

0015In accordance with an embodiment of the present invention, a dual-personality memory system supports both standard USB 2.0 devices and high speed extended USB (EUSB) devices that are formed in accordance with the method provided above. A host side of the dual-personality memory system includes a multiple pin (e.g., nine-pin) USB female socket that is similar to a standard female USB socket, but in addition to the standard (four) USB contact pins utilized to facilitate communications with standard USB 2.0 devices, the extended multiple pin USB socket includes one or more additional rows of contacts that facilitate extended communications (i.e., including additional transmitting/receiving differential pairs) between the host system and dual personality “extended” USB (EUSB) devices (e.g., memory cards). Each EUSB device <b>101</b> includes both standard USB contacts, a second row of extended function contacts, and a special controller that facilitates communication with a host system using either the standard serial USB communication protocol using the four standard USB contacts (e.g., when the EUSB memory card is plugged into a “standard” USB female socket), or extended communications using both the standard contacts and the second row of contacts (e.g., when the EUSB memory card is plugged into the multiple pin USB female socket of a dual-personality memory system).

0016In accordance with a specific embodiment of the present invention, a EUSB device <b>101</b> includes both standard USB metal contacts and a row of metal contact springs that exposed by openings formed in the top (first) portion of the molded housing, and extend from the EUSB memory card in a way that facilitates reliable extended (e.g., nine bit) communications. The EUSB device <b>101</b> includes a printed circuit board assembly (PCBA) including at least one dual-personality communication integrated circuit (IC) mounted on a lower surface of the PCB, four standard USB fixed contacts disposed on an upper surface of the PCB near the PCB's front edge, and several (e.g., five) metal contact springs positioned behind the standard USB contacts. In accordance with an aspect of the invention, the PCB is formed with parallel slots (openings) that are disposed behind the standard USB contacts, and the metal contact springs are mounted such that a portion of each metal contact spring extends through a corresponding slot and through a corresponding opening such that a contact portion of each contact spring protrudes above the upper planar surface defined by the top portion of the molded housing. A dual-personality communication IC is configured to selectively communicate either with a standard USB host system by way of the standard USB contacts (only), or with a dual-personality flash memory card system by way of all (e.g., nine) contact pads/springs. By forming the contact springs such that they extend through the slots/openings and protrude above the housing surface, the contact springs are provided with sufficient tolerance to both reliably contact corresponding contact pads of a host female socket, and are also able to bend downward (i.e., into the molded housing) when the contact springs are pressed against the corresponding contact pads of a host female socket.

0017In accordance with another embodiment of the present invention, the EUSB device <b>101</b> is manufactured by forming a contact spring assembly in which the contact springs are mounted on a base (e.g., a PCB or plastic) substrate, and the assembly is then mounted onto the device PCB such that the springs protrude through the parallel slots (openings) defined in the PCB. The PCB includes standard USB contact pads formed on its upper surface between its front edge and the row of slots, and contact pads formed on its lower PCB surface for mounting one or more ICs and passive components. According to an aspect of the invention, the spring assembly is mounted onto the lower surface of the PCB such that each contact spring extends through a corresponding slot such that a contact portion thereof protrudes from the upper PCB surface (and above the upper planar surface of the top housing portion after the molding process is completed), and such that the base covers the slots during a subsequent plastic molding step. By forming the PCBA in this manner, the springs are quickly and reliably mounted onto the PCB, and the base of the spring assembly covers the slots. The PCBA is then placed in a mold cavity, and a single-shot molded housing is formed such that a top housing portion is formed on the top PCB surface (i.e., except over the standard USB metal contact pads and contact springs), and a bottom housing portion is formed over the bottom PCB surface such that the passive components and ICs are entirely encased in housing material. The upper mold die used to form the top portion of the molded housing includes parallel bars and protrusions (poles) that respectively cover and prevent the formation of molding material on the contact pads and contact springs. The resulting EUSB memory card forms a modular structure including a connector plug with the standard USB metal contact pads and the contact springs being arranged such that, when said connector plug is inserted into said extended multiple pin USB socket, each of the standard USB contact pads contacts a corresponding standard USB contact of the extended multiple pin USB socket, and each of the contact springs contacts a corresponding dual-personality contact of the extended multiple pin USB socket. By forming the EUSB memory card in this manner, final assembly of the EUSB memory card into any of several external housings is greatly simplified, which reduces manufacturing costs by simplifying the assembly process.

0018According to an aspect of the invention, passive components are mounted onto the PCB using one or more standard surface mount technology (SMT) techniques, and one or more unpackaged IC die (e.g., the dual-personality communication IC die and a flash memory die) are mounted using chip-on-board (COB) techniques. During the SMT process, the SMT-packaged passive components (e.g., capacitors, oscillators, and light emitting diodes) are mounted onto contact pads disposed on the PCB, and then known solder reflow techniques are utilized to connect leads of the passive components to the contact pads. During the subsequent COB process, the IC dies are secured onto the PCB using know die-bonding techniques, and then electrically connected to corresponding contact pads using, e.g., known wire bonding techniques. After the COB process is completed, the housing is formed over the passive components and IC dies using plastic molding techniques. By combining SMT and COB manufacturing techniques to produce modular USB core components, the present invention provides several advantages over conventional manufacturing methods that utilize SMT techniques only. First, by utilizing COB techniques to mount the USB controller and flash memory, the large PCB area typically taken up by SMT-packaged controllers and flash devices is dramatically reduced, thereby facilitating significant miniaturization of the resulting footprint (i.e., providing a shorter device length and thinner device width). Second, the IC die height is greatly reduced, thereby facilitating stacked memory arrangements that greatly increase memory capacity of the EUSB memory cards without increasing the EUSB memory card footprint. Further, overall manufacturing costs are reduced by utilizing unpackaged controllers and flash devices (i.e., by eliminating the cost associated with SMT-package normally provided on the controllers and flash devices). Therefore, the combined COB and SMT method according to the present invention provides a less expensive and higher quality (i.e., more reliable) memory product with a smaller size than that possible using conventional SMT-only manufacturing methods.

0019According to another embodiment of the present invention, front edges of the parallel ribs formed on the upper surface of a USB or EUSB device are linked by a cross-rib that serves to protect the front edge of the PCBA, to prevent a user's finger from touching the four standard USB contact pads, and to provide extra thickness for the five “extended” pins to form higher loop so that the spring action is more flexible.

0020According to yet another embodiment of the present invention, the standard USB metal contact pads of a USB or EUSB device comprise raised middle rails that facilitate better contact with the spring metal contacts of a female USB connector socket.

0021According to an embodiment of the present invention, the EUSB device <b>101</b> is disposed in a plastic molded external housing so as to form a device assembly including a standard USB metal plug shell and a cover. By forming the EUSB memory card in the manner described above, the present invention greatly simplifies the assembly process utilized to form the device assembly, thus reducing overall costs.

BRIEF DESCRIPTION OF THE DRAWINGS

0022These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings, where:

0023<figref idref="DRAWINGS">FIGS. 1(A)</figref>, <b>1</b>(B), <b>1</b>(C) are perspective top, cross sectional side and cross sectional side views, respectively, showing a dual-personality USB memory system including an EUSB memory card according to a simplified embodiment of the present invention;

0024<figref idref="DRAWINGS">FIG. 2</figref> is a simplified block diagram showing a host system of the dual-personality USB memory system of <figref idref="DRAWINGS">FIG. 1</figref>;

0025<figref idref="DRAWINGS">FIGS. 3(A) and 3(B)</figref> are exploded perspective and assembled perspective views showing an EUSB memory card according to a specific embodiment of the present invention;

0026<figref idref="DRAWINGS">FIG. 4</figref> is a flow diagram depicting a method for producing the extended USB dual-personality extended USB memory card of <figref idref="DRAWINGS">FIG. 3(A)</figref> according to another embodiment of the present invention;

0027<figref idref="DRAWINGS">FIGS. 5(A) and 5(B)</figref> are top perspective and partial top perspective views showing a PCB panel utilized in the method of <figref idref="DRAWINGS">FIG. 4</figref>;

0028<figref idref="DRAWINGS">FIGS. 6(A) and 6(B)</figref> are bottom perspective and partial bottom perspective views showing the PCB panel of <figref idref="DRAWINGS">FIG. 5(A)</figref>;

0029<figref idref="DRAWINGS">FIGS. 7(A) and 7(B)</figref> are exploded perspective and assembled perspective views showing a contact spring assembly utilized in the method of <figref idref="DRAWINGS">FIG. 4</figref> according to an embodiment of the present invention;

0030<figref idref="DRAWINGS">FIGS. 8(A) and 8(B)</figref> are top perspective and bottom perspective views depicting mounting of the contact spring assembly of <figref idref="DRAWINGS">FIG. 7(B)</figref> onto the PCB panel of <figref idref="DRAWINGS">FIG. 5(A)</figref> according to an embodiment of the present invention;

0031<figref idref="DRAWINGS">FIGS. 9(A) and 9(B)</figref> are bottom perspective and partial bottom perspective views showing the PCB panel of <figref idref="DRAWINGS">FIG. 5(A)</figref> after the contact spring assembly of <figref idref="DRAWINGS">FIG. 7(B)</figref> is mounted thereon;

0032<figref idref="DRAWINGS">FIGS. 10(A) and 10(B)</figref> are top perspective and partial top perspective views showing the PCB panel of <figref idref="DRAWINGS">FIG. 5(A)</figref> after the contact spring assembly of <figref idref="DRAWINGS">FIG. 7(B)</figref> is mounted thereon;

0033<figref idref="DRAWINGS">FIGS. 11(A) and 11(B)</figref> partial bottom perspective and bottom perspective views showing the PCB panel of <figref idref="DRAWINGS">FIG. 10(A)</figref> during a subsequent SMT process;

0034<figref idref="DRAWINGS">FIGS. 12(A)</figref>, <b>12</b>(B), <b>12</b>(C) and <b>12</b>(D) are simplified perspective and cross-sectional side views depicting a semiconductor wafer and a process of grinding and dicing the wafer to produce IC dies utilized in the method of <figref idref="DRAWINGS">FIG. 4</figref>;

0035<figref idref="DRAWINGS">FIGS. 13(A) and 13(B)</figref> are partial bottom perspective and bottom perspective views depicting a die bonding process utilized to mount the IC dies of <figref idref="DRAWINGS">FIG. 12(D)</figref> onto the PCB panel of <figref idref="DRAWINGS">FIG. 11(B)</figref> according to the method of <figref idref="DRAWINGS">FIG. 4</figref>;

0036<figref idref="DRAWINGS">FIGS. 14(A) and 14(B)</figref> are partial bottom perspective and bottom perspective views depicting a wire bonding process utilized to connect the IC dies to corresponding contact pads disposed on the PCB of <figref idref="DRAWINGS">FIG. 13(B)</figref> according to the method of <figref idref="DRAWINGS">FIG. 4</figref>;

0037<figref idref="DRAWINGS">FIG. 15</figref> is an exploded perspective view showing an exemplary molding die assembly utilized to the perform single shot molding process in accordance with the method of <figref idref="DRAWINGS">FIG. 4</figref>;

0038<figref idref="DRAWINGS">FIGS. 16(A) and 16(B)</figref> are perspective and enlarged perspective views, respectively, showing an upper mold die of the molding die assembly of <figref idref="DRAWINGS">FIG. 15</figref> according to another embodiment of the present invention;

0039<figref idref="DRAWINGS">FIGS. 17(A) and 17(B)</figref> are simplified cross-sectional side views depicting a molding process for forming a molded housings over the PCB panel of <figref idref="DRAWINGS">FIG. 14(B)</figref> utilizing the molding die assembly of <figref idref="DRAWINGS">FIG. 15</figref> according to the method of <figref idref="DRAWINGS">FIG. 4</figref>;

0040<figref idref="DRAWINGS">FIGS. 18(A) and 18(B)</figref> are bottom and top perspective views, respectively, showing the PCB panel of <figref idref="DRAWINGS">FIG. 16(B)</figref> after being removed from the molding die assembly;

0041<figref idref="DRAWINGS">FIG. 19</figref> is a cross-sectional side view showing a singulation process according to the method of <figref idref="DRAWINGS">FIG. 4</figref>;

0042<figref idref="DRAWINGS">FIGS. 20(A) and 20(B)</figref> are top and bottom perspective views showing a EUSB following a marking process according to an embodiment of the present invention;

0043<figref idref="DRAWINGS">FIG. 21</figref> is a block diagram showing a dual-personality controller circuit of a EUSB memory card according to an embodiment of the present invention;

0044<figref idref="DRAWINGS">FIG. 22</figref> is simplified cross-sectional side view showing an EUSB memory card including stacked-memory according to another embodiment of the present invention;

0045<figref idref="DRAWINGS">FIG. 23</figref> is simplified cross-sectional side view showing a single-chip EUSB memory card according to another embodiment of the present invention;

0046<figref idref="DRAWINGS">FIG. 24</figref> is a perspective view showing a “standard” type USB device including a molded housing formed in accordance with a modified single-shot molding process according to another embodiment of the present invention;

0047<figref idref="DRAWINGS">FIG. 25</figref> is perspective view showing a “standard” type USB device including a single-shot molded housing including a front cross-rib according to another embodiment of the present invention;

0048<figref idref="DRAWINGS">FIG. 26</figref> is perspective view showing an EUSB device including a single-shot molded housing including a front cross-rib according to another embodiment of the present invention;

0049<figref idref="DRAWINGS">FIG. 27</figref> is perspective view showing a “standard” USB device including a raised metal middle rail according to another embodiment of the present invention;

0050<figref idref="DRAWINGS">FIG. 28</figref> is perspective view showing an EUSB device including a raised metal middle rail according to another embodiment of the present invention;

0051<figref idref="DRAWINGS">FIGS. 29(A) and 29(B)</figref> are perspective views showing USB assemblies including a plastic molded external housing for receiving a USB device according to another embodiment of the present invention; and

0052<figref idref="DRAWINGS">FIGS. 30(A) and 30(B)</figref> are front perspective views showing a conventional USB male plug and a conventional USB female socket, respectively.

DETAILED DESCRIPTION OF THE DRAWINGS

0053The present invention relates to an improved method for manufacturing extended USB (EUSB) devices (e.g., memory cards), and in particular to EUSB devices (memory cards) manufactured by the method. The following description is presented to enable one of ordinary skill in the art to make and use the invention as provided in the context of a particular application and its requirements. As used herein, the terms “upper”, “upwards”, “lower”, “downward”, “front” and “back” are intended to provide relative positions for purposes of description, and are not intended to designate an absolute frame of reference. Various modifications to the preferred embodiment will be apparent to those with skill in the art, and the general principles defined herein may be applied to other embodiments. Therefore, the present invention is not intended to be limited to the particular embodiments shown and described, but is to be accorded the widest scope consistent with the principles and novel features herein disclosed.

0054<figref idref="DRAWINGS">FIGS. 1(A)</figref>, <b>1</b>(B) and <b>1</b>(C) show a dual-personality USB memory system <b>100</b> including an extended 9-pin (multiple pin) USB female socket <b>190</b> that communicates with both standard USB memory cards and dual-personality extended USB (EUSB) memory cards <b>101</b> that are manufactured and operate in accordance with the present invention. That is, in accordance with the exemplary embodiment, dual-personality USB memory system <b>100</b> is operated to process (receive and transmit) both standard USB 2.0 (four pin) signals and extended function signals through extended 9-pin USB socket <b>190</b> in a manner consistent with that described in co-owned U.S. Pat. No. 7,108,560, entitled “Extend USB Protocol Plug and Receptacle for implementing Single-Mode Communication”, which is incorporated herein by reference in its entirety. In particular, in accordance with the 9-pin embodiment disclosed herein, in additional to the four standard USB 2.0 signals (i.e., power, ground, D+ and D−), the extra five contact springs are utilized to transmit and additional ground (e.g., using the middle spring), a transmitting differential pair (T+ and T−), and a receiving differential pair (R+ and R−) using the left and right side contact spring pairs, respectively. Thus the term “extended USB” (EUSB) is used herein to mean at least one transmitting/receiving signal pair in addition to the four standard USB signals. With the additional of these signal pairs, transmitting/receiving modes can be executed concurrently without the wait state of transmitting on receiving to complete, and vice versa, thereby significantly enhancing communication speeds.

0055Referring to the right side of <figref idref="DRAWINGS">FIG. 1(A)</figref> and <figref idref="DRAWINGS">FIG. 1(B)</figref>, EUSB device <b>101</b> generally includes a printed circuit board assembly (PCBA) <b>110</b> and a single-shot molded plastic housing <b>150</b> including an upper portion <b>150</b>A and a lower portion <b>150</b>B. PCBA <b>110</b> includes a printed circuit board (PCB) <b>111</b> having opposing upper (first) surface <b>116</b> and an opposing lower (second) surface <b>118</b>, and includes a handle (rear) portion <b>112</b> and a male plug (front portion) connector <b>114</b>. According to an aspect of the present invention, male plug connector <b>114</b> includes four standard USB (metal) contacts <b>121</b> (disposed on upper surface <b>116</b> in accordance with standard techniques, and five extended-use (metal) contact springs <b>122</b> disposed such that portions thereof extend through slots (openings <b>115</b>) defined in PCB <b>111</b> and through openings <b>155</b> defined in upper housing portion <b>150</b>A, and arranged in a row behind standard USB contacts <b>121</b>. A dual-personality communication integrated circuit (IC) <b>131</b> is mounted on lower surface <b>118</b>, and conductive traces (not shown) are formed on PCB <b>111</b> using known techniques such that contacts <b>121</b> and <b>122</b> are connected to dual-personality communication IC <b>131</b>. In addition, a memory (e.g., flash) IC <b>135</b> is mounted on lower surface <b>118</b> and connected to dual-personality communication IC <b>131</b> and contacts <b>121</b> and <b>122</b> by conductive traces (not shown). Other features and details associated with extended USB device <b>101</b> are provided below.

0056Because many conventional USB (male) connectors and (female) sockets (also referred to as standard USB plug connectors and standard USB sockets herein) are widely deployed, it is advantageous for the improved extended USB connector to be compatible with standard USB sockets, and an extended USB socket to be compatible with standard USB connectors for backward compatibility. Although the height and width of USB connectors/sockets have to remain the same for insertion compatibility, the length of each may be extended to fit additional metal contacts for additional signals. Furthermore, additional metal contacts (pins or springs) may be disposed on the plug connector, either adjacent to opposite the existing four standard USB metal contacts. As indicated in <figref idref="DRAWINGS">FIG. 1(A)</figref>, plug connector <b>114</b> of EUSB device <b>101</b> represents such extended plug connector that includes the four standard USB metal contact pads <b>121</b> and the five additional (extended-use) contact springs <b>122</b> that are disposed in a row behind standard USB metal contact pads <b>121</b>.

0057Referring to <figref idref="DRAWINGS">FIG. 1(B)</figref>, to support communications with EUSB device <b>101</b>, extended 9-pin USB female socket <b>190</b> includes four standard USB metal contact pins <b>191</b> and five additional (dual-personality) contact pads <b>192</b> that are disposed on the bottom surface of a pin substrate <b>194</b> to engage standard USB metal contact pads <b>121</b> and additional contact springs <b>122</b> when plug connector <b>114</b> is inserted therein. Female socket <b>190</b> also includes an outer (e.g., metal) casing <b>196</b> that cooperates with substrate <b>194</b> to define a cavity (slot) <b>197</b> for receiving plug connector <b>114</b>. <figref idref="DRAWINGS">FIG. 1(B)</figref> shows plug connector <b>114</b> inserted into 9-pin USB socket <b>190</b> such that standard USB metal contact pins <b>191</b> of socket <b>190</b> contact standard USB metal contacts <b>121</b> of extended USB device <b>101</b>, and additional contact pads <b>192</b> of socket <b>190</b> contact additional contact springs <b>122</b> of extended USB device <b>101</b>, thereby facilitating 9-pin communication between extended USB device <b>101</b> and a host system controller (not shown) that is connected to socket <b>190</b>.

0058As indicated in <figref idref="DRAWINGS">FIGS. 1(B) and 1(C)</figref>, each contact spring <b>122</b> extends through a corresponding slot/opening <b>115</b>/<b>155</b> and protrudes above a planar upper surface <b>152</b>A defined by upper housing portion <b>150</b>A by an amount that is sufficient to reliably contact corresponding contact pads <b>192</b> when EUSB device <b>101</b> is inserted into host female socket <b>190</b>. That is, each metal contact spring <b>122</b> includes a base portion <b>123</b> that is disposed on the lower side of PCB <b>111</b>, and includes a contact portion <b>124</b> that protrudes through its corresponding slot/opening <b>115</b>/<b>155</b> and extends above upper surface <b>152</b>A. Each metal contact spring <b>122</b> is connected to at least one of dual-personality communication IC <b>131</b> and memory IC <b>135</b> by corresponding conductive traces (not shown). <figref idref="DRAWINGS">FIG. 1(B)</figref> shows EUSB device <b>101</b> partially inserted into host female socket <b>190</b>, and shows that a lower surface of contact pad <b>192</b> is below the upper point of contact portion <b>124</b>, whereby when EUSB device <b>101</b> is fully inserted (as shown in FIG. <b>1</b>(C)), contact portion <b>124</b> reliably contacts contact pad <b>192</b>, and contact spring <b>122</b> bends downward slightly into opening <b>115</b>. By forming each contact spring <b>122</b> in this manner, contact portion <b>124</b> is provided with sufficient tolerance (i.e., extends far enough above upper surface <b>116</b>) to assure contact with corresponding contact pad <b>192</b>, and the ability to flex downward when such contact occurs, thereby providing a suitable design variance that produces reliable connection between extended-USB socket <b>190</b> and EUSB device <b>101</b>.

0059In accordance with an aspect of the present invention, both upper portion <b>150</b>A and lower portion <b>150</b>B of single-shot molded housing <b>150</b> include planar surfaces that are simultaneously formed during a single-shot molding process described below, where the molding die (cover plate) used to form upper housing portion <b>150</b>A is provided with structures arranged to prevent the formation of molding material on contact pads <b>121</b> and contact springs <b>122</b>. In particular, as shown in <figref idref="DRAWINGS">FIG. 1(A)</figref>, upper portion <b>150</b>A is formed such that several parallel elongated ribs <b>157</b> extend between associated pairs of metal contact pads <b>121</b>. By providing elongated ribs <b>157</b> between metal contact pads <b>121</b> in this manner, the present invention protects metal contact pads <b>121</b> from undesirable wear due to repeated insertion into a host female socket, thereby extending the operating life of EUSB device <b>101</b>.

0060<figref idref="DRAWINGS">FIG. 2</figref> is a block diagram of an exemplary host system <b>105</b> with one embodiment of extended-USB socket <b>190</b> that supports extended-mode communication. Although the description below refers only to communications with standard USB memory cards <b>60</b> and EUSB device <b>101</b>, those skilled in the art will recognize that the sockets and extended USB memory card features described herein can be altered to accommodate one or more of a variety of other flash memory devices (e.g., SD, MMC, SATA, PCI-Express, Firewire IEEE 1394, or Serial-Attached SCSI). As shown in <figref idref="DRAWINGS">FIG. 2</figref>, host system <b>105</b> includes a processor <b>106</b> for executing programs including USB-management and bus-scheduling programs. Dual-personality serial-bus interface <b>107</b> processes data from processor <b>106</b> using two protocol processors including a standard USB protocol processor <b>109</b>A and an EUSB protocol processor <b>109</b>B. USB processor <b>109</b>A processes data using the USB protocol, and inputs and outputs USB data on the four standard USB contacts <b>191</b> in extended USB socket <b>190</b> (which communicate with standard USB metal contacts <b>121</b> of an inserted standard USB memory card <b>60</b> or EUSB device <b>101</b>). In contrast, the extended metal contact pins <b>192</b> of extended USB socket <b>190</b> (which communicate with contact springs <b>122</b> of EUSB device <b>101</b>, when inserted therein) are connected to dual-personality bus switch <b>107</b>. Transceivers in dual-personality bus switch <b>107</b> buffer data transmitted and received as pairs of differential signals sent over data lines connected to the extended metal contacts to facilitate the EUSB protocol. When an initialization routine executed by processor <b>106</b> determines that inserted flash memory device supports the EUSB protocol, personality selector <b>108</b> configures dual-personality bus switch <b>107</b> to connect extended USB socket <b>190</b> to EUSB processor <b>109</b>B. Processor <b>106</b> communicates with EUSB processor <b>109</b>B instead of USB processor <b>109</b>A when extended mode is activated. Additional details regarding the operation of host <b>105</b> will be apparent to those skilled in the art based on the teachings in U.S. Pat. No. 7,108,560 (cited above) and the description provided below.

0061<figref idref="DRAWINGS">FIGS. 3(A) and 3(B)</figref> are exploded perspective and assembled perspective views showing a simplified EUSB device <b>101</b>A that is produced according to a simplified specific embodiment of the present invention. As set forth below, and with reference to the flow diagram of <figref idref="DRAWINGS">FIG. 4</figref>, EUSB device <b>101</b>A is manufactured by forming a contact spring assembly <b>120</b> in which contact springs <b>122</b> are mounted on a base (e.g., a PCB or plastic) substrate <b>125</b>, and spring assembly <b>120</b> is then mounted onto PCB <b>111</b> such that contact portions <b>124</b> of each contact spring <b>122</b> protrude through corresponding slots/openings <b>115</b>/<b>155</b>, and base <b>125</b> covers the lower side of openings <b>115</b> during a subsequent single-shot plastic molding step (described below) that is used to form single-shot molded housing <b>150</b>.

0062Similar to the general embodiment described above with reference to <figref idref="DRAWINGS">FIGS. 1(A) and 1(B)</figref>, EUSB device <b>101</b>A includes a PCBA <b>110</b> made up of a PCB <b>111</b> with standard USB contacts <b>121</b> formed on its upper surface <b>116</b> between front edge portion <b>111</b>P-<b>1</b> and the row of openings <b>115</b>, and one or more ICs <b>130</b> (e.g., dual-personality communication IC <b>131</b> and memory IC <b>135</b>) and passive components <b>140</b> mounted on lower PCB surface <b>118</b>. PCB <b>111</b> is formed in accordance with known PCB manufacturing techniques such that metal contacts <b>121</b>, IC dies <b>130</b>, and passive components <b>140</b> are electrically interconnected by a predefined network including conductive traces and other conducting structures that are sandwiched between multiple layers of an insulating material (e.g., FR4) and adhesive. For example, contact pads <b>119</b>-<b>1</b> and <b>119</b>-<b>2</b> are disposed on lower surface <b>118</b> and used to connect dual-personality communication IC <b>131</b> and memory IC <b>135</b>, respectively, using methods described below. Contact pads <b>119</b>-<b>3</b> are also provided on lower surface <b>118</b>, and used to facilitate the mounting of passive components <b>140</b>, as described in additional detail below.

0063As indicated in <figref idref="DRAWINGS">FIG. 3(A)</figref>, according to an aspect of the present invention, spring assembly <b>120</b> is mounted onto lower surface <b>118</b> of the PCB <b>111</b> such that each contact spring <b>122</b> extends through a corresponding opening <b>115</b> such that a contact portion <b>124</b> of each contact spring <b>122</b> protrudes from the upper PCB surface <b>116</b> in the manner described above with reference to <figref idref="DRAWINGS">FIG. 1(B)</figref>. In one embodiment, each contact spring <b>122</b> is a substantially C-shaped spring structure having a pair of base portions <b>123</b> that are secured to a substrate <b>125</b>, and a central contact portion <b>124</b> that forms an arched (bent) structure extending between base portions <b>123</b>. By forming the PCBA in this manner, when spring assembly <b>120</b> is mounted onto lower surface <b>118</b>, contact portions <b>124</b> extend a suitable distance above upper surface <b>116</b>, and substrate <b>125</b> covers openings <b>115</b>. As described in further detail below, PCBA <b>110</b> is then placed in a mold cavity, and a single-shot molded housing <b>150</b> is formed that includes a lower portion <b>150</b>B formed over lower surface <b>118</b> such that ICs <b>130</b> and passive components <b>140</b> are encased by plastic, and upper portion <b>150</b>A formed over upper surface <b>116</b> of PCB <b>111</b>, whereby upper portion <b>150</b>A is formed such that standard USB contacts <b>121</b> and contact springs <b>122</b> are exposed as described herein by opening <b>155</b> and by slots defined between ribs <b>157</b>. By forming EUSB device <b>101</b>A in this manner, PCBA <b>111</b> is protected on both sides by respective portions of molded housing <b>150</b>, and final assembly of the EUSB memory card into any of several external housings (see example below) is greatly simplified, which reduces manufacturing costs by simplifying the assembly process.

0064Housing <b>150</b> is molded plastic formed and arranged such that substantially all of the plastic used to form housing <b>150</b> is located either below (i.e., on one side of) lower surface <b>118</b> of PCB <b>111</b>, or above upper surface <b>116</b> of PCB <b>111</b>. As indicated in <figref idref="DRAWINGS">FIG. 3(B)</figref>, lower housing portion <b>150</b>B includes a peripheral surface <b>151</b> extending downward (i.e., perpendicular to PCB <b>111</b>), and a planar lower surface <b>152</b>B that extends parallel to PCB <b>111</b>. For discussion purposes, the portion of peripheral surface <b>151</b> surrounding handle section <b>112</b> of PCB <b>111</b> is referred to below as handle surface section <b>151</b>-<b>1</b>, and the section of peripheral surface <b>151</b> surrounding plug section <b>114</b> of PCB <b>111</b> is referred to below as plug surface section <b>151</b>-<b>2</b>. Similarly, the portion of lower surface <b>152</b>B covering handle section <b>112</b> of PCB <b>111</b> is referred to below as handle surface section <b>152</b>-<b>1</b>B, and the section of lower surface <b>152</b>B covering plug section <b>114</b> of PCB <b>111</b> is referred to below as plug cover section <b>152</b>-<b>2</b>B.

0065Referring to <figref idref="DRAWINGS">FIG. 3(A)</figref>, according to another aspect of the invention, passive components <b>140</b> are mounted onto lower surface <b>118</b> of PCB <b>111</b> using one or more standard surface mount technology (SMT) techniques, and one or more unpackaged IC dies <b>130</b> are mounted on PCB <b>111</b> using chip-on-board (COB) techniques. During the SMT process, passive components <b>140</b>, such as resistors, capacitors, and oscillator are mounted onto associated contact pads <b>119</b>-<b>3</b> disposed on lower surface <b>118</b>, and are then secured to the contact pads using known solder reflow techniques. To facilitate the SMT process, each of the passive components is packaged in any of the multiple known (preferably lead-free) SMT packages (e.g., ball grid array (BGA) or thin small outline package (TSOP)). In contrast, IC dies <b>130</b> are unpackaged, semiconductor “chips” that are mounted onto surface <b>118</b> and electrically connected to corresponding contact pads using known COB techniques. Passive components <b>140</b>, IC dies <b>131</b> and <b>135</b> and metal contacts <b>121</b> and <b>122</b> are operably interconnected by way of metal traces that are formed on and in PCB <b>111</b> using known techniques.

0066Referring to <figref idref="DRAWINGS">FIG. 3(B)</figref>, a thickness T<b>1</b> and width W<b>1</b> of connector plug <b>114</b> is selected to produce a secure (snug) fit inside either an external case (discussed below) or directly into socket <b>190</b> (see <figref idref="DRAWINGS">FIG. 1</figref>). According to another aspect of the present invention, planar upper surface <b>152</b>A and planar lower surface <b>152</b>B are parallel to PCB <b>111</b>, and are spaced such that a first thickness T<b>1</b> of connector plug <b>114</b> (i.e., measured between upper housing surface <b>152</b>A and lower housing surface <b>152</b>B adjacent to metal contacts <b>121</b>) is substantially equal to a second thickness T<b>2</b> adjacent a rear end of handle section <b>114</b>. That is, as indicated in <figref idref="DRAWINGS">FIG. 3(B)</figref>, EUSB device <b>101</b>A is substantially flat along its entire length (i.e., measured from the rear edge of handle section <b>112</b> to the front edge of plug section <b>114</b>). In the embodiment shown in <figref idref="DRAWINGS">FIG. 3(B)</figref>, the uppermost surface of EUSB device <b>101</b>A is defined by upper housing surface <b>152</b>A, which is parallel to planar lower housing surface <b>152</b>B along the entire length of EUSB device <b>101</b>A.

0067According to an aspect of the present invention, the “flatness” associated with modular USB core component <b>102</b> is achieved by mounting all of the IC dies (“chips”) and other electronic components of modular USB core component <b>102</b> on lower surface <b>118</b> of PCB <b>111</b> (i.e., on the side opposite to metal contacts <b>121</b>), and forming a thin layer of molding material on upper surface <b>116</b>. That is, the minimum overall thickness of modular USB core component <b>102</b> is determined by the thickness T<b>1</b> that is required to maintain a snug connection between connector plug <b>114</b> and female USB socket connector <b>190</b> (see <figref idref="DRAWINGS">FIG. 1</figref>). This arrangement requires that ribs <b>157</b> extend a predetermined distance above upper surface <b>116</b>, and that plug wall section <b>151</b>-<b>2</b>B plug and lower wall section <b>152</b>-<b>2</b>B of lower housing portion <b>150</b>B extend a predetermined distance below PCB <b>111</b> such that the distance between upper surface <b>152</b>A and lower wall section <b>152</b>-<b>2</b>B provide the required thickness T<b>1</b>. The present inventors have found that the overall thickness of modular USB core component <b>102</b> can be minimized by mounting the IC dies <b>130</b> and <b>135</b> and passive components (e.g., capacitor <b>142</b>) only on lower surface <b>118</b> of PCB <b>111</b>, and by minimizing the thickness of the upper housing portion <b>150</b>A such that upper surface <b>152</b>A is slightly above the surface of metal contact pads <b>121</b>. That is, if the IC dies and passive components are mounted on upper surface <b>116</b>, then the overall thickness of the resulting USB structure would be the required thickness T<b>1</b> plus the thickness that the ICs extend above PCB <b>111</b> (plus the thickness of a protective wall, if used).

0068According to another aspect associated with the embodiment shown in <figref idref="DRAWINGS">FIG. 3(B)</figref>, upper surface <b>116</b> of PCB <b>111</b> in handle section <b>112</b> is covered by upper housing portion <b>150</b>B, thus facilitating the production of EUSB device <b>101</b> with a maximum thickness equal to thickness T<b>1</b> of plug portion <b>114</b>. That is, because upper housing portion <b>150</b>A is formed on upper surface <b>116</b> with a uniform thickness, and upper surface <b>152</b>A defines the higher end of required plug structure thickness T<b>1</b>, the overall height of EUSB device <b>101</b> is minimized. As indicated in <figref idref="DRAWINGS">FIG. 3(B)</figref>, in accordance with feature specifically associated with EUSB device <b>101</b>, upper housing portion <b>150</b>A is disposed on upper surface <b>116</b>, but does not extend over peripheral (side) edge <b>111</b>P of PCB <b>111</b>, and peripheral wall <b>151</b> (e.g., front edge <b>151</b>-<b>2</b> and rear edge <b>151</b>-<b>1</b>) extends around up to but does not cover peripheral edge <b>111</b>P of PCB <b>111</b>.

0069<figref idref="DRAWINGS">FIG. 4</figref> is a flow diagram showing a method for producing a EUSB memory card according to another embodiment of the present invention. Summarizing the novel method, a PCB panel is fabricated including multiple PCBs, each PCB defining openings (block <b>210</b>; described below with reference to <figref idref="DRAWINGS">FIGS. 5 and 6</figref>). Contact springs are then mounted onto the PCB panel such that each contact spring extends through a corresponding opening and contact portions of each contact spring protrude above the upper surface of the PCB (block <b>220</b>; described below with reference to <figref idref="DRAWINGS">FIGS. 7-10</figref>). ICs and passive components are then attached to the PCBs (block <b>225</b>-<b>245</b>; described below with reference to <figref idref="DRAWINGS">FIGS. 11-14</figref>), and then a single-shot molded housing is formed on the PCB such that the passive components and ICs are covered, and such that substantially all of the PCB's upper surface is exposed.

0070According to another aspect of the invention, the passive components are then mounted on the PCB panel using SMT techniques (block <b>225</b>), and then unpackaged IC dies are die bonded and wire bonded onto the PCB panel using COB techniques (block <b>240</b>). Plastic molding is then performed to form a plastic housing over the PCB panel in a single molding step (single-shot) (block <b>260</b>), which is then singulated into individual EUSB memory cards (block <b>260</b>). This portion of the method provides several advantages over conventional manufacturing methods that utilize SMT techniques only. First, by utilizing COB techniques to mount the USB controller and flash memory, the large amount of space typically taken up by these devices is dramatically reduced, thereby facilitating significant miniaturization of the resulting EUSB memory card footprint. Second, by implementing the wafer grinding methods described below, the die height is greatly reduced, thereby facilitating stacked memory arrangements such as those described below. The molded housing also provides greater moisture and water resistance and higher impact force resistance than that achieved using conventional manufacturing methods. In comparison to the standard USB memory card manufacturing that used SMT process, it is cheaper to use the combined COB and SMT (plus molding) processes described herein because, in the SMT-only manufacturing process, the bill of materials such as Flash memory and the EUSB controller chip are also manufactured by COB process, so all the COB costs are already factored into the packaged memory chip and controller chip. Therefore, the combined COB and SMT method according to the present invention provides a less expensive and higher quality (i.e., more reliable) extended USB memory card product with a smaller size than that possible using conventional SMT-only manufacturing methods.

0071Referring to the lower end of <figref idref="DRAWINGS">FIG. 4</figref>, the EUSB memory cards are marked (block <b>270</b>), and then tested, packed and shipped (block <b>280</b>). Optional final assembly is then performed by producing/procuring an external housing, and mounting a EUSB memory card into the external housing.

0072The flow diagram of <figref idref="DRAWINGS">FIG. 4</figref> will now be described in additional detail below with reference to the following figures.

0073Referring to the upper portion of <figref idref="DRAWINGS">FIG. 4</figref>, the manufacturing method begins with filling a bill of materials including producing/procuring PCB panels (block <b>210</b>), producing/procuring passive (discrete) components (block <b>212</b>) such as resistors, capacitors, diodes, LEDs and oscillators that are packaged for SMT processing, producing spring assemblies (block <b>218</b>), and producing/procuring a supply of IC wafers (or individual IC dies; see blocks <b>230</b> to <b>234</b>, discussed below).

0074<figref idref="DRAWINGS">FIG. 5(A)</figref> is a top perspective view showing a PCB panel <b>300</b>(<i>t</i><b>0</b>) provided in block <b>210</b> of <figref idref="DRAWINGS">FIG. 4</figref> according to a specific embodiment of the present invention. <figref idref="DRAWINGS">FIG. 5(B)</figref> is a top perspective view showing a selected PCB <b>111</b>-<b>1</b> of PCB panel <b>300</b>(<i>t</i><b>0</b>). <figref idref="DRAWINGS">FIGS. 6(A) and 6(B)</figref> are top perspective views showing panel <b>300</b> and selected PCB <b>111</b>-<b>1</b>, respectively. The suffix “tx” is utilized herein to designated the state of the PCB panel during the manufacturing process, with “t<b>0</b>” designating an initial state. Sequentially higher numbered prefixes (e.g., “t<b>1</b>”, “t<b>2</b>” and “t<b>3</b>”) indicate that PCB panel <b>300</b> has undergone additional processing.

0075As indicated in <figref idref="DRAWINGS">FIGS. 5(A) and 6(A)</figref>, PCB panel <b>300</b>(<i>t</i><b>0</b>) includes a two-by-five matrix of regions designated as PCBs <b>111</b>, each having the features described above with reference to <figref idref="DRAWINGS">FIG. 3(A)</figref>. <figref idref="DRAWINGS">FIGS. 5(A) and 5(B)</figref> show upper surface <b>116</b> of each PCB <b>111</b> (e.g., upper surface <b>116</b> of panel <b>111</b>-<b>1</b> includes standard USB metal contacts <b>121</b>, described above), and <figref idref="DRAWINGS">FIGS. 6(A) and 6(B)</figref> show lower surfaces <b>118</b> of PCBs <b>111</b> (represented by PCB <b>111</b>-<b>1</b> in <figref idref="DRAWINGS">FIG. 6(B)</figref>). Note that lower surface <b>118</b> of each PCB <b>111</b> (e.g., PCB <b>111</b>-<b>1</b>) includes multiple contact pads <b>119</b>-<b>1</b>, <b>119</b>-<b>2</b> and <b>119</b>-<b>3</b> arranged in predetermined patterns for facilitating SMT and COB processes, as described below.

0076As indicated in <figref idref="DRAWINGS">FIG. 5(A)</figref>, in addition to the two rows of PCBs <b>111</b>, panel <b>300</b>(<i>t</i><b>0</b>) includes end border regions <b>310</b> and side border regions <b>320</b> that surround the PCBs <b>111</b>, and a central region <b>340</b> disposed between the two rows of PCBs <b>111</b>. Designated cut lines are scored or otherwise partially cut into PCB panel <b>300</b>(<i>t</i><b>0</b>) along the borders of each of these regions, but do not pass through the panel material. For example, end cut lines <b>311</b> separate end border panels <b>310</b> from associated PCBs <b>111</b>, side cut lines <b>321</b> separate side border panels <b>310</b> from associated PCBs <b>111</b>, and central cut lines <b>341</b> separate central region <b>340</b> from associated PCBs <b>111</b>. PCB cut lines <b>331</b> are formed along the side edges between adjacent PCBs <b>111</b>. The border panels are provided with positioning holes and other features known to those skilled in the art to facilitate the manufacturing process, and are removed during singulation (described below).

0077According to an aspect of the invention, each PCB <b>111</b> of panel <b>300</b>(<i>t</i><b>0</b>) defines a predetermined number of openings <b>115</b> that extend between upper surface <b>116</b> and lower surface <b>118</b> (e.g., as depicted by <figref idref="DRAWINGS">FIGS. 5(B) and 6(B)</figref>). Openings <b>115</b> are in the form of elongated slots that are positioned behind standard USB contacts <b>121</b> (i.e., as indicated in <figref idref="DRAWINGS">FIG. 5(B)</figref>, standard USB contacts <b>121</b> are positioned between openings <b>115</b> and front edge <b>111</b>P-<b>1</b> of substrate <b>111</b>-<b>1</b>). As discussed herein openings <b>115</b> are utilized in the mounting of contact springs.

0078Note that PCBs for USB memory cards that are produced using SMT-only manufacturing processes must be significantly wider than PCBs <b>111</b> due to the space required to mount already packaged flash memory devices. By utilizing COB methods to mount the flash memory, the present invention facilitates significantly narrower PCBs <b>111</b>, thereby allowing each PCB panel <b>300</b>(<i>t</i><b>0</b>) to include an increased number of PCBs <b>111</b> per PCB panel, thereby providing shorter manufacturing times and lower manufacturing costs.

0079<figref idref="DRAWINGS">FIGS. 7(A) to 10(B)</figref> illustrate the assembly and mounting of spring assemblies onto PCB panel <b>300</b>(<i>t</i><b>0</b>) according to an embodiment of the invention. <figref idref="DRAWINGS">FIGS. 7(A) and 7(B)</figref> are exploded perspective and perspective views depicting the formation of a spring assembly <b>120</b> according to an embodiment of the present invention. Spring assembly <b>120</b> includes five substantially C-shaped contact springs <b>122</b> having a pair of base portions <b>123</b> that are secured to a substrate <b>125</b>, and a central contact portion <b>124</b> that forms an arched (bent) structure extending between base portions <b>123</b> and held away from substrate <b>125</b>. In one embodiment, substrate <b>125</b> is plastic or another non-conducting material), and contact springs <b>122</b> are secured by adhesive to substrate <b>125</b> in a pattern and spacing that precisely matches the pattern and spacing of openings <b>115</b> defined on PCB <b>111</b>A (discussed above). In one embodiment, both base portions <b>123</b> are coated with low temperature (i.e., approximately 160° C.) lead-free solder, and substrate <b>125</b> is one-sided adhesive tape of high temperature resistance type (i.e., able to sustain temperatures greater than 180° C.). <figref idref="DRAWINGS">FIGS. 8(A) and 8(B)</figref> are perspective top and bottom views, respectively, illustrating the subsequent process of mounting a spring assembly <b>120</b> onto PCB <b>111</b>-<b>1</b> of PCB panel <b>300</b>(<i>t</i><b>0</b>) (shown in <figref idref="DRAWINGS">FIG. 6(B)</figref>). As indicated, spring assembly <b>120</b> is mounted onto PCB <b>111</b>-<b>1</b> such that a portion of each contact spring <b>122</b> extends through a corresponding elongated slot (opening) <b>115</b>. To facilitate the transfer of signals between contact springs <b>122</b> and the subsequently-mounted IC dies, each contact spring <b>122</b> is electrically connected to an associated conductive trace (not shown) formed on PCB <b>111</b>-<b>1</b>. In one embodiment, metal pads (not shown) are disposed on each PCB <b>111</b> at both ends of each slot <b>115</b>. These pads are connected to the dual-personality communication integrated circuit (IC) <b>131</b> electrically (not shown) by way of corresponding traces. These pads are soldered to the top surface of each base portion <b>123</b> of each contact spring <b>122</b>. <figref idref="DRAWINGS">FIG. 9(A)</figref> shows panel <b>300</b>(<i>t</i><b>1</b>) after spring assemblies <b>120</b> are mounted on each PCB <b>111</b> (e.g., spring assembly <b>120</b>-<b>1</b> is mounted on lower surface <b>118</b> of PCB <b>111</b>-<b>1</b>, as shown in additional detail in <figref idref="DRAWINGS">FIG. 9(B)</figref>). As indicated in <figref idref="DRAWINGS">FIGS. 10(A) and 10(B)</figref>, contact portion <b>124</b> of each contact spring <b>122</b> protrudes through a corresponding slot <b>115</b> and extends above upper surface <b>116</b> of each PCB <b>111</b> (e.g., PCB <b>111</b>-<b>1</b>).

0080<figref idref="DRAWINGS">FIG. 11(A)</figref> is a perspective view depicting a portion of panel <b>300</b>(<i>t</i><b>1</b>) that is used to mount passive components on PCB <b>111</b>-<b>1</b> according to block <b>225</b> of <figref idref="DRAWINGS">FIG. 4</figref>. During the first stage of the SMT process, lead-free solder paste is printed on contact pads <b>119</b>-<b>3</b>, which in the present example correspond to SMT components <b>140</b>, using custom made stencil that is tailored to the design and layout of PCB <b>111</b>-<b>1</b>. After dispensing the solder paste, the panel is conveyed to a conventional pick-and-place machine that mounts each SMT component <b>140</b> onto a corresponding pair of contact pads <b>119</b>-<b>3</b> according to known techniques. Upon completion of the pick-and-place component mounting process, the PCB panel is then passed through an IR-reflow oven set at the correct temperature profile. The solder of each pad on the PC board is fully melted during the peak temperature zone of the oven, and this melted solder connects all pins of the passive components to the finger pads of the PC board. <figref idref="DRAWINGS">FIG. 11(B)</figref> shows PCB <b>111</b>-<b>1</b> of the resulting PCB panel <b>300</b>(<i>t</i><b>2</b>), which now includes passive components <b>140</b> mounted thereon by the completed SMT process.

0081<figref idref="DRAWINGS">FIG. 12(A)</figref> is a simplified perspective view showing a semiconductor wafer <b>400</b>(<i>t</i><b>0</b>) procured or fabricated according to block <b>230</b> of <figref idref="DRAWINGS">FIG. 4</figref>. Wafer <b>400</b>(<i>t</i><b>0</b>) includes multiple ICs <b>430</b> that are formed in accordance with known photolithographic fabrication (e.g., CMOS) techniques on a semiconductor base <b>401</b>. In the example described below, wafer <b>400</b>(<i>t</i><b>1</b>) includes ICs <b>430</b> that comprise, e.g., dual-personality communication ICs. In a related procedure, a wafer (not shown) similar to wafer <b>400</b>(<i>t</i><b>1</b>) is produced/procured that includes flash memory circuits, and in an alternative embodiment (described in additional detail below), ICs <b>430</b> may include both dual-personality communication ICs and flash memory circuits. In each instance, these wafers are processed as described herein with reference to <figref idref="DRAWINGS">FIGS. 12(B)</figref>, <b>12</b>(C) and <b>12</b>(D).

0082As indicated in <figref idref="DRAWINGS">FIGS. 12(B) and 12(C)</figref>, during a wafer back grind process according to block <b>232</b> of <figref idref="DRAWINGS">FIG. 4</figref>, base <b>401</b> is subjected to a grinding process in order to reduce the overall initial thickness TW<b>1</b> of each IC <b>430</b>. Wafer <b>400</b>(<i>t</i><b>1</b>) is first mount face down on sticky tape (i.e., such that base layer <b>401</b>(<i>t</i><b>0</b>) faces away from the tape), which is pre-taped on a metal or plastic ring frame (not shown). The ring-frame/wafer assembly is then loaded onto a vacuum chuck (not shown) having a very level, flat surface, and has diameter larger than that of wafer <b>400</b>(<i>t</i><b>0</b>). The base layer is then subjected to grinding until, as indicated in <figref idref="DRAWINGS">FIG. 12(C)</figref>, wafer <b>400</b>(<i>t</i><b>1</b>) has a pre-programmed thickness TW<b>2</b> that is less than initial thickness TW<b>1</b> (shown in <figref idref="DRAWINGS">FIG. 12(B)</figref>). The wafer is cleaned using de-ionized (DI) water during the process, and wafer <b>400</b>(<i>t</i><b>1</b>) is subjected to a flush clean with more DI water at the end of mechanical grinding process, followed by spinning at high speed to air dry wafer <b>400</b>(<i>t</i><b>1</b>).

0083Next, as shown in <figref idref="DRAWINGS">FIG. 12(D)</figref>, the wafer is diced (cut apart) along predefined border regions separating ICs <b>430</b> in order to produce IC dies <b>130</b> according to block <b>234</b> of <figref idref="DRAWINGS">FIG. 4</figref>. After the back grind process has completed, the sticky tape at the front side of wafer <b>400</b>(<i>t</i><b>1</b>) is removed, and wafer <b>400</b>(<i>t</i><b>1</b>) is mounted onto another ring frame having sticky tape provided thereon, this time with the backside of the newly grinded wafer contacting the tape. The ring framed wafers are then loaded into a die saw machine. The die saw machine is pre-programmed with the correct die size information, X-axis and Y-axis scribe lanes' width, wafer thickness and intended over cut depth. A proper saw blade width is then selected based on the widths of the XY scribe lanes. The cutting process begins dicing the first lane of the X-axis of the wafer. De-ionized wafer is flushing at the proper angle and pressure around the blade and wafer contact point to wash and sweep away the silicon saw dust while the saw is spinning and moving along the scribe lane. The sawing process will index to the second lane according to the die size and scribe width distance. After all the X-axis lanes have been completed sawing, the wafer chuck with rotate 90 degree to align the Y-axis scribe lanes to be cut. The cutting motion repeated until all the scribe lanes on the Y-axis have been completed.

0084<figref idref="DRAWINGS">FIG. 13(A)</figref> is a perspective view depicting a die bonding process utilized to mount IC dies <b>131</b> and <b>135</b> on PCB <b>111</b>-<b>1</b> of the PCB panel <b>300</b>(<i>t</i><b>2</b>) (described above with reference to <figref idref="DRAWINGS">FIG. 11(B)</figref>) according to block <b>240</b> of <figref idref="DRAWINGS">FIG. 5</figref>. The die bonding process generally involves mounting IC dies <b>131</b> into lower surface region <b>118</b>A, which is surrounded by contact pads <b>119</b>-<b>1</b>, and mounting IC die <b>135</b> into lower surface region <b>118</b>B, which is surrounded by contact pads <b>119</b>-<b>2</b>. In one specific embodiment, an operator loads IC dies <b>131</b> and <b>135</b> onto a die bonder machine according to known techniques. The operator also loads multiple PCB panels <b>300</b>(<i>t</i><b>2</b>) onto the magazine rack of the die bonder machine. The die bonder machine picks the first PCB panel <b>300</b>(<i>t</i><b>2</b>) from the bottom stack of the magazine and transports the selected PCB panel from the conveyor track to the die bond (DB) epoxy dispensing target area. The magazine lowers a notch automatically to get ready for the machine to pick up the second piece (the new bottom piece) in the next cycle of die bond operation. At the die bond epoxy dispensing target area, the machine automatically dispenses DB epoxy, using pre-programmed write pattern and speed with the correct nozzle size, onto the target areas <b>118</b>A and <b>118</b>B of each of the PCB <b>111</b> of PCB panel <b>300</b>(<i>t</i><b>2</b>). When all PCBs <b>111</b> have completed this epoxy dispensing process, the PCB panel is conveyed to a die bond (DB) target area. Meanwhile, at the input stage, the magazine is loading a second PCB panel to this vacant DB epoxy dispensing target area. At the die bond target area, the pick up arm mechanism and collet (suction head with rectangular ring at the perimeter so that vacuum from the center can create a suction force) picks up an IC die <b>131</b> and bonds it onto area <b>118</b>A, where epoxy has already dispensed for the bonding purpose, and this process is then performed to place IC die <b>135</b> into region <b>118</b>B. Once all the PCB boards <b>111</b> on the PCB panel have completed die bonding process, the PCB panel is then conveyed to a snap cure region, where the PCB panel passes through a chamber having a heating element that radiates heat having a temperature that is suitable to thermally cure the epoxy. After curing, the PCB panel is conveyed into the empty slot of the magazine waiting at the output rack of the die bonding machine. The magazine moves up one slot after receiving a new panel to get ready for accepting the next panel in the second cycle of process. The die bonding machine will repeat these steps until all of the PCB panels in the input magazine are processed. This process step may repeat again for the same panel for stack die products that may require to stacks more than one layer of memory die. <figref idref="DRAWINGS">FIG. 13(B)</figref> is a top perspective views showing PCB <b>111</b>-<b>1</b> of PCB panel <b>300</b>(<i>t</i><b>3</b>) after the die bonding process is completed.

0085<figref idref="DRAWINGS">FIG. 14(A)</figref> is a perspective view depicting a wire bonding process utilized to connect the IC dies <b>131</b> and <b>135</b> to corresponding contact pads <b>119</b>-<b>1</b> and <b>119</b>-<b>2</b>, respectively, according to block <b>245</b> of <figref idref="DRAWINGS">FIG. 4</figref>. The wire bonding process proceeds as follows. Once a full magazine of PCB panels <b>300</b>(<i>t</i><b>3</b>) (see <figref idref="DRAWINGS">FIG. 13(B)</figref>) has completed the die bonding operation, an operator transports the PCB panels <b>300</b>(<i>t</i><b>3</b>) to a nearby wire bonder (WB) machine, and loads the PCB panels <b>300</b>(<i>t</i><b>3</b>) onto the magazine input rack of the WB machine. The WB machine is pre-prepared with the correct program to process this specific EUSB memory card. The coordinates of all the ICs' pads <b>119</b>-<b>1</b> and <b>119</b>-<b>2</b> and PCB gold fingers were previously determined and programmed on the WB machine. After the PCB panel with the attached dies is loaded at the WB bonding area, the operator commands the WB machine to use optical vision to recognize the location of the first wire bond pin of the first memory die of the first PCB on the panel. Once the first pin is set correctly, the WB machine can carry out the whole wire bonding process for the rest of the panels of the same product type automatically. For multiple flash layer stack dies, the PCB panels may be returned to the WB machine to repeat wire bonding process for the second stack. <figref idref="DRAWINGS">FIG. 14(B)</figref> is a top perspective views showing PCB panel <b>300</b>(<i>t</i><b>4</b>) after the wire bonding process is completed.

0086<figref idref="DRAWINGS">FIG. 15</figref> is an exploded perspective top view showing a top cover plate (upper molding die) <b>451</b> and bottom cover plate (lower molding die) <b>452</b> of a mold machine <b>450</b> utilized to perform a single-shot molding process according to an embodiment of the present invention, and <figref idref="DRAWINGS">FIGS. 16(A) and 16(B)</figref> are bottom perspective views showing the top cover plate <b>451</b> in additional detail. <figref idref="DRAWINGS">FIGS. 17(A) and 17(B)</figref> are simplified cross-sectional side views depicting a molding process for forming a molded housing layer over PCB panel <b>300</b>(<i>t</i><b>4</b>) using mold machine <b>450</b> according to block <b>250</b> of <figref idref="DRAWINGS">FIG. 4</figref>.

0087As indicated in <figref idref="DRAWINGS">FIG. 15</figref>, after the wire bonding process is completed, USB panel <b>300</b>(<i>t</i><b>4</b>) is loaded into mold machine <b>450</b> between top cover plate <b>451</b> and bottom cover plate <b>452</b>. Top cover plate <b>451</b> mounts onto the upper side of PCB panel <b>300</b>(<i>t</i><b>4</b>), and as shown in <figref idref="DRAWINGS">FIGS. 16(A) and 16(B)</figref>, defines several cavities <b>453</b>, each having portions disposed over upper surfaces <b>116</b> of adjacent pairs of PCB regions <b>111</b>. In accordance with an aspect of the invention, top cover plate <b>451</b> includes parallel bars <b>454</b> and protrusions (poles) <b>455</b> that are disposed each portion of cavity <b>453</b>, and that respectively abut contact pads <b>121</b> and contact springs <b>122</b> when top cover plate <b>451</b> is mounted over PCB panel <b>300</b>(<i>t</i><b>4</b>) in order to prevent the formation of molding material on these contact structures. In contrast, as shown in <figref idref="DRAWINGS">FIG. 15</figref>, bottom cover plate <b>452</b> mounts onto the lower side of PCB panel <b>300</b>(<i>t</i><b>4</b>), and defines cavities <b>456</b> that respectively cover lower surfaces <b>118</b> of adjacent pairs of PCB regions <b>111</b> such that the IC chips, wire bonds and passive components that are mounted on lower surface <b>118</b> of each PCB are received inside a corresponding cavity <b>456</b>.

0088<figref idref="DRAWINGS">FIGS. 17(A) and 17(B)</figref> depict a transfer molding process performed after cover plates <b>451</b> and <b>452</b> are secured over panel <b>300</b>(<i>t</i><b>4</b>). Transfer molding is used due to the high accuracy of transfer molding tooling and low cycle time. The molding material in the form of pellet is preheated and loaded into a pot or chamber (not shown). <figref idref="DRAWINGS">FIG. 17(A)</figref> shows panel <b>300</b>(<i>t</i><b>4</b>) secured between cover plates <b>451</b> and <b>452</b> of mold machine <b>450</b> such that each parallel bar <b>454</b> is pressed against a corresponding contact pad <b>121</b>, each protrusion <b>455</b> covers a corresponding opening <b>115</b>, mold cavities <b>453</b> are disposed over remaining sections of upper surface <b>116</b> onto which molding material is to be formed, and mold cavities <b>456</b> are disposed over ICs <b>130</b> and <b>135</b> and over the remaining structures disposed on lower surface <b>116</b> onto which molding material is to be formed. As depicted in <figref idref="DRAWINGS">FIG. 17(B)</figref>, a plunger (not shown) is then used to force the material from the pot through channels known as a spruce and runner system into the mold cavities <b>453</b> and <b>456</b>, causing the molten (e.g., plastic) material to form molded housing portions <b>150</b>A and <b>150</b>B over each PCB that encapsulates all the IC chips and components disposed on lower surface <b>118</b>, and to cover selected portions of upper surface <b>116</b>. Note that parallel bars <b>454</b> and protrusions <b>455</b> serve to prevent molding material from forming on contact pads <b>121</b> and contact springs <b>122</b> during the molding process. In addition, substrates <b>125</b> (discussed above) cover openings <b>115</b> through each PCB region <b>111</b>, thereby preventing molten plastic from entering openings <b>115</b> from cavity <b>456</b> and forming on contact springs <b>122</b>, which could prevent electrical connection when inserted into a host female socket. Mold machine <b>450</b> remains closed as the material is inserted and filled up all vacant in cavities <b>453</b> and <b>456</b>. During the process, the walls of cover plates <b>451</b> and <b>452</b> are heated to a temperature above the melting point of the mold material, which facilitates a faster flow of material through cavities <b>453</b> and <b>456</b>. Mold machine <b>450</b> remains closed until a curing reaction within the molding material is complete. A cooling down cycle follows the injection process, and the molding materials of molded casings <b>150</b> start to solidify and harden. Ejector pins push PCB panel <b>300</b>(<i>t</i><b>5</b>) (shown in <figref idref="DRAWINGS">FIGS. 18(A) and 18(B)</figref>) from the mold machine once molded casings <b>150</b> have hardened sufficiently over the PCBs (e.g., lower housing portion <b>150</b>-<b>1</b>B (<figref idref="DRAWINGS">FIG. 18(A)</figref>) and upper housing portion <b>150</b>-<b>1</b>A (<figref idref="DRAWINGS">FIG. 18(B)</figref>) are solidified on PCB <b>111</b>-<b>1</b>).

0089<figref idref="DRAWINGS">FIG. 19</figref> is simplified cross-sectional side view depicting a singulation process according to block <b>260</b> of <figref idref="DRAWINGS">FIG. 4</figref> that is used to separate PCB panel <b>300</b>(<i>t</i><b>5</b>) into individual sub-assemblies <b>101</b>A. PCB panel <b>300</b>(<i>t</i><b>5</b>) is loaded into a saw machine (not shown) that is pre-programmed with a singulation routine that includes predetermined cut locations. The saw blade is aligned to the first cut line (e.g., end cut line <b>311</b>-<b>1</b>) as a starting point by the operator. The coordinates of the first position are stored in the memory of the saw machine. The saw machine then automatically proceeds to cut up (singulate) the USB panel <b>300</b>(<i>t</i><b>5</b>), for example, successively along cut lines <b>311</b>-<b>1</b>, <b>341</b>-<b>1</b>, <b>341</b>-<b>2</b>, and <b>311</b>-<b>2</b>, and then along the side cut lines and PCB cut lines (see <figref idref="DRAWINGS">FIG. 5(A)</figref>) to form individual sub-assemblies <b>101</b>A, which are shown and described above with reference to <figref idref="DRAWINGS">FIGS. 3(A) and 3(B)</figref>, according to the pre-programmed singulation routine. Note that, as shown in <figref idref="DRAWINGS">FIG. 3(B)</figref>, due to the singulation process which includes cutting along all four sides of each PCB region, the peripheral surface <b>111</b>P of each PCB <b>111</b> is exposed in the final product (i.e., all of the molding material forming upper housing portion <b>150</b>A is disposed above PCB <b>111</b>, and all molding material forming lower housing portion <b>150</b>B is disposed below PCB <b>111</b>).

0090Referring to block <b>280</b> located at the bottom of <figref idref="DRAWINGS">FIG. 4</figref>, final procedures in the manufacturing method of the present invention involve optional marking (block <b>270</b>), testing, packing and shipping the individual extended USB memory cards. An exemplary marked EUSB device <b>101</b>A is shown in <figref idref="DRAWINGS">FIGS. 20(A) and 20(B)</figref>, including company name and country of manufacture printed on upper surface <b>152</b>A of upper housing portion <b>150</b>A, and additional information, such as memory size (storage capacity), lot number and manufacturing date printed on lower surface <b>152</b>B of lower housing portion <b>150</b>B. Visually or/and electrically test rejects are removed from the good population as defective rejects. The good extended USB memory cards are then packed into custom made boxes which are specified by customers. The final packed products will ship out to customers following correct procedures with necessary documents.

0091<figref idref="DRAWINGS">FIG. 21</figref> is a block diagram showing a simplified dual-purpose controller <b>130</b>-<b>2</b> according to another embodiment of the present invention. CPU <b>710</b> communications with a dual-personality transceiver <b>720</b> by way of an internal bus <b>740</b>. Dual-personality transceiver <b>720</b> operates in a manner similar to that described above with reference to host system <b>105</b> (<figref idref="DRAWINGS">FIG. 2</figref>) to communicate with both standard USB contact pads <b>121</b> and extended purpose contact springs <b>122</b> in order to communicate with a host system, e.g., by way of socket <b>190</b> (see <figref idref="DRAWINGS">FIG. 2</figref>). Note that controller <b>130</b>-<b>2</b> includes a memory controller <b>750</b> for controlling read/write operations to flash memory circuits that are part of the PCBA hosting dual-purpose controller <b>130</b>-<b>2</b>, thereby facilitating the dual-personality (i.e., EUSB-type and USB-type) communications that are described above.

0092<figref idref="DRAWINGS">FIG. 22</figref> is simplified cross-sectional side view showing a stacked-memory EUSB device <b>101</b>-<b>2</b> in which dual-purpose controller <b>130</b>-<b>2</b> accesses a first flash memory chip <b>535</b>-<b>1</b> and a second flash memory chip <b>535</b>-<b>2</b>. First flash memory chip <b>535</b>-<b>1</b> is mounted on a lower surface <b>118</b> of a PCB <b>111</b>-<b>2</b> and connected by first wire bonds <b>560</b>-<b>1</b> to PCB <b>111</b>-<b>2</b> in the manner described above. Because the IC die height (thickness) D is much smaller than packaged flash memory devices, and because the thickness T<b>1</b> of EUSB memory card <b>500</b> is set, for example, at 2.0 mm to assure a snug fit of the extended USB memory card inside a female USB socket (e.g., socket <b>190</b>, shown in FIG. <b>1</b>(A)), the present invention facilitates a stacked memory arrangement in which second flash memory die <b>535</b>-<b>2</b> is mounted on first flash memory die <b>535</b>-<b>1</b> and connected to PCB <b>111</b>-<b>2</b> by way of second wire bonds <b>560</b>-<b>2</b>. In an alternative embodiment (not shown), second flash memory die <b>535</b>-<b>2</b> may be connected to contacts provided on first flash memory die <b>535</b>-<b>1</b> by associated wire bonds. This stacked memory arrangement greatly increases memory capacity of the extended USB memory cards without increasing the footprint (i.e., thickness T<b>1</b>, length and width) of EUSB device <b>101</b>-<b>2</b>. EUSB device <b>101</b>-<b>2</b> is then processed and assembled as described above to produce a corresponding completed extended USB memory card.

0093<figref idref="DRAWINGS">FIG. 23</figref> is simplified cross-sectional side view showing a EUSB device <b>101</b>-<b>3</b> including stacked-memory according to another embodiment of the present invention. EUSB device <b>101</b>-<b>3</b> is distinguished over the previous embodiments in that, instead of separate controller and flash memory chips, EUSB device <b>101</b>-<b>3</b> utilizes a single-chip dual-purpose controller/flash die <b>630</b> that is connected to a PCB <b>111</b>-<b>3</b> by way of wire bonds <b>660</b> in the manner described above, and is characterized in that single-chip dual-purpose controller/flash die <b>630</b> includes both a dual-purpose controller circuit and one or more flash block mass storage circuits that are interconnected by a bus.

0094Although the present invention is described above with reference to a specific EUSB device, the two-sided single-shot molding process of the present invention may be utilized to produce other devices as well, some of which are described below with reference to <figref idref="DRAWINGS">FIGS. 25 to 29</figref>.

0095<figref idref="DRAWINGS">FIG. 24</figref> is a perspective view showing a USB device <b>101</b>-<b>4</b> including a PCBA <b>110</b>-<b>4</b> sandwiched between an upper housing portion <b>150</b>-<b>4</b>A and a lower housing portion <b>150</b>-<b>4</b>B, which make up a single-shot molded housing <b>150</b>-<b>4</b> formed in the manner similar to that described above (i.e., such that lower molding portion <b>150</b>B covers at least IC disposed on the lower side of PCBA <b>110</b>-<b>4</b>). In addition, similar to the above-described embodiments, first housing portion <b>150</b>A includes a several elongated ribs <b>157</b> extending between associated pairs of metal contact pads <b>121</b>. However, USB device <b>101</b>-<b>4</b> differs from the previous EUSB embodiments in that PCBA <b>110</b>-<b>4</b> does not include a row of metal contact springs disposed behind “standard” USB contacts <b>121</b>, and the controller IC (not shown) of USB device <b>101</b>-<b>4</b> is simplified to perform only “normal” USB communication processes with a host system. Thus, USB device <b>101</b>-<b>4</b> illustrates the case where the single-shot molding process and associated ribs can be implemented in a “standard” type USB device.

0096<figref idref="DRAWINGS">FIGS. 25 and 26</figref> are perspective view showing USB devices including upper housing portions that include front cross-rib structures for protect the front edge of the associated PCBA, to prevent a user's finger from touching the front 4-pin standard USB contact pads, and to provide extra thickness for the five “extended” pins to form higher loops so that the spring action is more flexible. In particular, <figref idref="DRAWINGS">FIG. 25</figref> shows a “standard” type USB device <b>101</b>-<b>5</b> including a PCBA <b>110</b>-<b>5</b> sandwiched between an upper housing portion <b>150</b>-<b>5</b>A and a lower housing portion <b>150</b>-<b>5</b>B, which make up a single-shot molded housing <b>150</b>-<b>5</b> formed in the manner similar to that described above (i.e., such that upper housing portion <b>150</b>-<b>5</b>A includes a several elongated ribs <b>157</b>-<b>5</b> extending between associated pairs of metal contact pads <b>121</b>). USB device <b>101</b>-<b>5</b> differs from previous embodiments in that upper housing portion <b>150</b>-<b>5</b>A further includes a front cross-rib <b>158</b> extending along the front edge portion <b>111</b>P-<b>1</b> of PCBA <b>110</b>-<b>5</b>, where front cross-rib <b>158</b> connects front portions of elongated ribs <b>157</b>-<b>5</b>. Similarly, <figref idref="DRAWINGS">FIG. 26</figref> shows an EUSB type device <b>101</b>-<b>6</b> including a PCBA <b>110</b>-<b>6</b> and a single-shot molded housing <b>150</b>-<b>6</b> made up of an upper housing portion <b>150</b>-<b>6</b>A and a lower housing portion <b>150</b>-<b>6</b>B, where upper housing portion <b>150</b>-<b>5</b>A includes elongated ribs <b>157</b>-<b>6</b> that are connected by a cross-rib <b>158</b>. As in the previous embodiments, metal contact pads <b>121</b> are exposed between ribs <b>157</b>-<b>6</b>, and metal contact springs <b>122</b> are disposed behind metal contact pads <b>121</b>.

0097<figref idref="DRAWINGS">FIGS. 27 and 28</figref> are perspective view showing USB devices that include raised metal rails for facilitating better contact between the spring metal pads and a host female USB connector (not shown). In particular, <figref idref="DRAWINGS">FIG. 27</figref> shows a “standard” type USB device <b>101</b>-<b>7</b> including a PCBA <b>110</b>-<b>7</b> sandwiched between an upper housing portion <b>150</b>-<b>7</b>A and a lower housing portion <b>150</b>-<b>7</b>B of a single-shot molded housing <b>150</b>-<b>5</b>. USB device <b>101</b>-<b>7</b> differs from previous embodiments in that PCBA <b>110</b>-<b>7</b> includes raised metal rails <b>127</b> that are processed using stamped and downset gold plated metal with the outer dimensions (OD) slightly larger than the underlying standard metal contact pads <b>121</b>. Each raised metal rail <b>127</b> is soldered on top of a corresponding metal contact pad <b>121</b> during the SMT process. Similarly, <figref idref="DRAWINGS">FIG. 28</figref> shows an EUSB type device <b>101</b>-<b>8</b> including a PCBA <b>110</b>-<b>8</b> and a single-shot molded housing <b>150</b>-<b>8</b>, where PCBA <b>110</b>-<b>8</b> includes raised middle rails <b>127</b>.

0098<figref idref="DRAWINGS">FIGS. 29(A) and 29(B)</figref> depict a Universal-Serial-Bus (EUSB) assembly <b>700</b>-<b>1</b> according to another specific embodiment that utilizes any of the USB/EUSB devices described above (indicated in <figref idref="DRAWINGS">FIG. 29(A)</figref> as USB/EUSB device <b>101</b>) as a modular structure that is fixedly connected inside an external plastic case such that, as indicated in <figref idref="DRAWINGS">FIG. 29(A)</figref>, metal contacts <b>121</b> of USB/EUSB device <b>101</b> are accessible through a front opening <b>735</b> defined a plug section <b>730</b> of case <b>710</b>. Assembly <b>700</b> includes an integrally molded box-like body <b>710</b> having a handle section <b>720</b> and plug section <b>730</b>. Body <b>710</b> defines an internal cavity <b>715</b> that extends from a back side of handle section <b>720</b> and into plug section <b>730</b>. Plug section <b>730</b> includes a front end plate <b>732</b> that defines elongated front openings <b>735</b>. During assembly, the front end of USB/EUSB device <b>101</b> is inserted into a rear opening of handle section <b>720</b> from the rear side, and is slid forward until metal contacts are exposed through openings <b>735</b>. Note that, in EUSB embodiments, contact springs would also be exposed through corresponding openings formed in front end plate <b>732</b>. As indicated in <figref idref="DRAWINGS">FIG. 29(B)</figref> assembly <b>700</b>-<b>2</b> includes straight sides, but is otherwise identical to assembly <b>700</b>-<b>1</b>.

0099Although the present invention has been described with respect to certain specific embodiments, it will be clear to those skilled in the art that the inventive features of the present invention are applicable to other embodiments as well, all of which are intended to fall within the scope of the present invention. For example, although the present invention is described with specific reference to nine-pin extended USB memory cards, the present invention is also applicable to other EUSB devices, and using other extended USB communication systems (i.e., including a number of contact springs <b>122</b> other than five, as disclosed herein).